Collapsible container

ABSTRACT

A collapsible container includes a base having a pair of opposed first edges and a pair of opposed second edges. The base has a generally planar portion having a plurality of first drainage channels formed along the first edges, a plurality of second drainage channels formed along the second edges and a plurality of third drainage channels formed perpendicularly to the first drainage channels between the second drainage channels. The second drainage channels and the third drainage channels are in fluid communication with the first drainage channels. The first, second and third drainage channels form drag rails on an underside of the base that are the lowest surfaces of the base.

BACKGROUND

Reusable plastic containers are often used for shipping packages of food to stores. Frozen or refrigerated meat may be stored in plastic bags that are then placed in the reusable plastic container. The plastic bags may be damaged by sharp edges on the interior surfaces of the plastic container. Further, the plastic bags may leak liquid into the plastic container.

SUMMARY

A collapsible container includes a base having a pair of opposed first edges and a pair of opposed second edges. The base has a generally planar portion having a plurality of first drainage channels formed along the first edges, a plurality of second drainage channels formed along the second edges and a plurality of third drainage channels formed perpendicularly to the first drainage channels between the second drainage channels. The second drainage channels and the third drainage channels are in fluid communication with the first drainage channels. The first, second and third drainage channels form drag rails on an underside of the base that are the lowest surfaces of the base.

The drag rails on the underside of the base may be spaced apart to define a longitudinal stacking channel extending through the entire longitudinal dimension of the underside of the base. The drag rails on the underside of the base may also be spaced apart to define a plurality of lateral stacking channels each extending through the entire lateral dimension of the underside of the base. The stacking channels permit the containers to be cross-stacked and provide for a more stable stack.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a collapsible container according to one embodiment.

FIG. 2 is a top view of the collapsible container of FIG. 1.

FIG. 3 is a side view of the collapsible container of FIG. 1.

FIG. 4 is one end view of the collapsible container of FIG. 1.

FIG. 5 is the other end view of the collapsible container of FIG. 1.

FIG. 6 is a bottom view of the collapsible container of FIG. 1.

FIG. 7 shows an intermediate stage of collapsing the collapsible container of FIG. 1.

FIG. 8 shows the collapsible container of FIG. 1 in a collapsed position.

FIG. 9 is a top view of the collapsed container of FIG. 8.

FIG. 10 is a side view of the collapsed container of FIG. 8.

FIG. 11 is an end view of the collapsed container of FIG. 8.

FIG. 12 is a perspective view of the base of the collapsible container of FIG. 1.

FIG. 13 is a top view of the base of FIG. 12.

FIG. 14 is a bottom view of the base of FIG. 12.

FIG. 15 shows two cross-stacked layers of a 7-down configuration of a plurality of the collapsible containers of FIG. 1.

FIG. 16 shows the stack of FIG. 15 with two containers removed.

FIG. 17 is a bottom perspective view of the stack of containers of FIG. 15, partially broken away.

DETAILED DESCRIPTION

An example embodiment of a collapsible container 10 is shown in FIG. 1. The container 10 includes a base 12, opposed side walls 14 and opposed end walls 16. The base 12 includes a base wall and side flanges 18 and end flanges 20 extending upward from side edges and end edges of the base wall, respectively. The side walls 14 are hingeably connected to the side flanges 18. The end walls 16 are hingeably connected to the end flanges 20. The end flanges 20 are taller than the side flanges 18. End flanges 20 and side flanges 18 are integrally molded as part of the base 12. Latches 22 selectively secure the side walls 14 to the end walls 16 in a known manner. Handle openings 26 may be formed in the end walls 16. Internal corrugations 34 near the upper edge of each long wall are configured to engage packages (e.g. bags) inside the container 10 to promote interlock potential to keep the bags in the interior of the upper rim. The internal corrugations 34 align with the height of the stacked meat patties and the seal point on the vacuum-sealed plastic bags, the corrugations 34 help to keep that seal point from walking up the wall and becoming pinched between the stacked layers of containers 10.

The base wall of the base 12 is a generally planar portion formed into a plurality of longitudinal drainage channels 38, 39 and intersecting lateral drainage channels 36, 37. Outer longitudinal drainage channels 38 connect to end lateral drainage channels 36 in the corners of the base 12. A center longitudinal drainage channel 39 is between two outer longitudinal drainage channels 38 along each side edge of the base 12. Interior lateral drainage channels 37 extend perpendicularly to the longitudinal drainage channels 38, 39, between the ends of the base 12. A different number and a different arrangement of channels 36, 37, 38, 39 could be used but the disclosed number and arrangement provides some benefits in this particular application.

Referring to FIG. 2, which is a top view of the container 10, the longitudinal drainage channels 38, 39 and intersecting lateral drainage channels 36, 37 divide the generally planar portion of the base 12 into a 4×2 array of spaced support surfaces 40. The support surfaces 40 may optionally be pitched slightly toward the drainage channels 36 and 38 that are lower than the support surfaces 40. A center support surface 42 extends the longitudinal center of the base 12 from one end wall 16 to the other at the same height as the support surfaces 40, separating the lateral drainage channels 36, 37 into two 5×1 arrays. The support surfaces 40, 42 constitute a large majority of the area of the base 12, e.g. more than 90%.

The longitudinal drainage channels 38, 39 extend adjacent the side walls 14 (i.e. adjacent the side flanges 18 (FIG. 1)), with three spaced-apart longitudinal drainage channels 38, 39 adjacent each side wall 14 and elongated in a direction parallel to the side walls 14.

The lateral drainage channels 36, 37 are each elongated in a direction parallel to the end walls 16. There are two spaced-apart end lateral drainage channels 36 adjacent each end wall 16 (i.e. adjacent each end flange 20 (FIG. 1)) and connected to the longitudinal drainage channels 38 in the corners. There are two spaced-apart interior lateral drainage channels 37 in the center of the container 10 and connected to the center longitudinal drainage channels 39. There are two spaced-apart interior lateral drainage channels 36 between the center and each of the end walls 16, which also connect to the longitudinal drainage channels 38 that connect to end lateral drainage channels 36. Each of the lateral drainage channels 36, 37 within each spaced-apart pair is spaced-apart from the other by the center support surface 42.

FIG. 3 is a side view of the container 10. The longitudinal drainage channels 38 (FIG. 1) form longitudinal drag rails 48 on the bottom of the container 10, forming the lowest surfaces of the container 10. Spaces between the longitudinal drag rails 48 form lateral stacking channels 54.

FIG. 4 is an end view of the container 10 and FIG. 5 is the other end view of the container 10. Spaces between the lateral drag rails 46 define a longitudinal stacking channel 52.

FIG. 6 is a bottom view of the container 10. The end lateral drainage channels 36 (FIG. 1) form the end lateral drag rails 46 on the bottom of the container 10. The interior lateral drainage channels 37 (FIG. 1) form interior lateral drag rails 47. The longitudinal drag rails 48, 49 correspond to the longitudinal drainage channels 36, 37 (FIG. 1), respectively. The drag rails 46, 47, 48, 49 provide the lowest surfaces of the container 10. The end lateral drag rails 46 and the longitudinal drag rails 48, 49 are spaced inwardly of the perimeter of the base 12. In particular, they are spaced just inward of the side flanges 18 and end flanges 20 of the base 12 (FIG. 1).

The spaces between the lateral drag rails 46, 47 form the longitudinal stacking channel 52 that extends entirely through the length of the base 12. Spaces between the longitudinal drag rails 48,49 form two lateral stacking channels 54 entirely through the width of the base 12.

FIG. 7 shows that the container 10 can be collapsed by first collapsing the side walls 14 on the base 12 and then collapsing one of the end walls 16 onto the side walls 14. As shown in FIG. 8, the other end wall 16 is then collapsed onto the side walls 14. The end walls 16 do not overlap and are spaced apart from one another in the collapsed position. In this collapsed position the container 10 can be efficiently shipped and stored when empty. FIG. 9 is a top view of the collapsed container 10. FIG. 10 is a side view of the collapsed container 10. FIG. 11 is an end view of the collapsed container 10.

FIG. 12 is a perspective view of the base 12 of the container 10 of FIG. 1. The base wall, side flanges 18 and end flanges 20 are all integrally molded as a single piece of plastic. There are no openings through the base 12.

Thus any liquids that may leak from contents in the container 10 will drain from the support surfaces 40 into the longitudinal drainage channel 38 and the lateral drainage channels 36. This initially keeps the liquids from the support surfaces 40 on which the contents of the container 10 are supported. The base wall of the base 12 does not include openings through it and thus will retain liquids in the base 12 until hinge openings through the flanges 18, 20 are reached. Optionally, slots can be added in the end flanges 20 or side flanges 18 of the base 12 at a specific height in order to control the volume of fluid capacity. The slots may be at the same height of the hinge openings, or they may be lower, depending on the desired volume to be retained. The slots will also help with drainage during the washing and drying process.

Additionally, the interior surface of the bottom of the base wall is product-friendly, with no sharp edges or protruding ribs throughout the entire bottom section of the base 12. As such, the bottom of the base 12 was designed with smooth drainage channels 36, 38 and raised support surfaces 40 to create a stiff design without the use of ribs or sharp edges. This soft bottom profile ensures that packages do not get ripped, torn, or damaged when placed inside the container.

FIG. 13 is a top view of the base 12. FIG. 14 is a bottom view of the base 12.

FIG. 15 shows two cross-stacked layers of a 7-down configuration of a plurality of the containers 10. In each layer, three containers 10 are arranged with abutting side walls 14. Adjacent these three containers 10 are four containers 10 in a 2×2 array, with the side walls 14 abutting the end walls 16 of the group of three containers 10.

As shown, the second layer is oriented 180 degrees relative to the first layer, such that the three containers 10 in the second layer are substantially arranged on top of the four containers 10 in the first layer, and the 2×2 containers 10 in the second layer are substantially arranged on top of the three containers 10 in the first layer.

In FIG. 16, two of the three containers 10 in the second layer have been removed to show the orientation of the containers 10 in the first layer.

FIG. 17 is a bottom perspective view of the containers of FIG. 15, partially broken away. As shown, the end wall 16 abuts a side wall 14 of another container in the lower layer, and these walls 14, 16 are received in the longitudinal stacking channel 52 of a container 10 in the upper layer. Abutting side walls 14 of two containers 10 in the lower layer are received in the lateral stacking channel 54 of a container 10 of the upper layer.

The base 12 is integrally molded as a single piece of suitable plastic, as are each of the side walls 14 and end walls 16.

In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. 

What is claimed is:
 1. A collapsible container comprising: a base having a pair of opposed first edges and a pair of opposed second edges, the base having a generally planar portion having a plurality of first drainage channels formed along the first edges, a plurality of second drainage channels formed along the second edges and a plurality of third drainage channels formed perpendicularly to the first drainage channels between the second drainage channels, wherein the second drainage channels and the third drainage channels are in fluid communication with the first drainage channels, wherein the first, second and third drainage channels form drag rails on an underside of the base that are the lowest surfaces of the base; a pair of first walls pivotably connected to the pair of opposed first edges of the base; and a pair of second walls pivotably connected to the pair of opposed second edges of the base.
 2. The collapsible container of claim 1 wherein the plurality of first drainage channels include three first drainage channels along each first edge.
 3. The collapsible container of claim 1 wherein the base further includes first flanges projecting upward at the first edges of the base and second flanges projecting upward at the second edges of the base, wherein the pair of first walls are pivotably connected to the first flanges and the pair of second walls are pivotably connected to the second flanges.
 4. The collapsible container of claim 1 wherein the second walls have handle openings formed therein.
 5. The collapsible container of claim 4 wherein the first, second and third drainage channels define a plurality of support surfaces therebetween, wherein the plurality of support surfaces constitute a majority of the surface area of the base.
 6. The collapsible container of claim 5 wherein the plurality of support surfaces constitute more than 90% of the surface area of the base.
 7. The collapsible container of claim 6 wherein the plurality of support surfaces includes a center support surface extending parallel to the first edges of the base and separating pairs of the plurality of second drainage channels.
 8. The collapsible container of claim 7 wherein the center support surface separates pairs of the plurality of third drainage channels.
 9. The collapsible container of claim 1 wherein the drag rails on the underside of the base are spaced apart to define a longitudinal stacking channel extending through the entire longitudinal dimension of the underside of the base.
 10. The collapsible container of claim 9 wherein the drag rails on the underside of the base are spaced apart to define a plurality of lateral stacking channels each extending through the entire lateral dimension of the underside of the base.
 11. The collapsible container of claim 10 wherein the plurality of first drainage channels include three first drainage channels along each first edge.
 12. The collapsible container of claim 11 wherein the base further includes first flanges projecting upward at the first edges of the base and second flanges projecting upward at the second edges of the base, wherein the pair of first walls are pivotably connected to the first flanges and the pair of second walls are pivotably connected to the second flanges.
 13. The collapsible container of claim 12 wherein the second walls have handle openings formed therein.
 14. The collapsible container of claim 13 wherein the base has no openings therethrough.
 15. The collapsible container of claim 10 cross-stacked on an identical collapsible container, such that the one of the first walls or one of the second walls of the identical collapsible container is received in one of the longitudinal stacking channel or one of the plurality of lateral stacking channels of the collapsible container.
 16. The collapsible container of claim 1 wherein the base has no openings therethrough.
 17. A collapsible container comprising: a base having a pair of opposed first edges and a pair of opposed second edges, the base having a generally planar portion having a plurality of first drainage channels formed along the first edges, a plurality of second drainage channels formed along the second edges and a plurality of third drainage channels formed perpendicularly to the first drainage channels between the second drainage channels, wherein the second drainage channels and the third drainage channels are in fluid communication with the first drainage channels, wherein the first, second and third drainage channels form drag rails on an underside of the base that are the lowest surfaces of the base, the first, second and third drainage channels defining a plurality of support surfaces therebetween, the plurality of support surfaces constituting more than 90% of the surface area of the base, wherein the plurality of support surfaces includes a center support surface extending parallel to the first edges of the base and separating pairs of the plurality of second drainage channels and pairs of the plurality of third drainage channels; a pair of first walls pivotably connected to the pair of opposed first edges of the base; and a pair of second walls pivotably connected to the pair of opposed second edges of the base.
 18. The collapsible container of claim 17 wherein the base further includes first flanges projecting upward at the first edges of the base and second flanges projecting upward at the second edges of the base, wherein the pair of first walls are pivotably connected to the first flanges and the pair of second walls are pivotably connected to the second flanges.
 19. The collapsible container of claim 18 wherein the second walls have handle openings formed therein.
 20. The collapsible container of claim 19 wherein the base has no openings therethrough. 